Apparatus for pyrolytic conversion of hydrocarbons



K. M. WATSON June 6, 1950 APPARATUS FOR PYROLYTIC CONVERSION OF HYDROCARBONS Filed June 27, 1947 FIG.I

FIG. 2

FIG. 3

REACTOR INVENTOR KENNETH MERLE WATSON ATTORNEYS Patented June 6, 1 950 2,5200444 APPARATUS roarmom'rm CONVERSION I'OF'HYDROCAYRBONS akcorporatismufrMaine melamine-11 mm 27, mflg-senama 572649- meme-rm ammo f-tlreeartzxoft oil refihl'tn'griamfli :prwicles hirpnwed zapparatue respeclally adapted to'use inithaltarti cially' 'lmSehEM iilit pymolytlcmomersiom operations" 5 =irivo3viarg themse -oi a finely 'seliy'i'cle'd iyst andrnmvicles: meanaior reflecting more' uniform contact? hetweenitheehyzdnoearbon" vapo'rs tiemation mimawunfls; for instance; efll-tiemt vapors mann ng the-e distillation m conversion of hydrooembomsr finely dilvidefi caztalyst is brimght imtorvmtimate wn-taot with: vaaporiz'eclhydnoea/rbons 'to -'be-"conyertegl-in a meaotion zone; seenlt loatalyst 'i'snsepa- 'rats'ed fnomvthe: oil:.1va1oorssthe-seisamwted catalyst medimn in strfi pingvzone; regenerated =b'y deearbohiaation m a megenerating zone and "the regenerated eatailyet'netursned-twthe-reach Lon zone fioneomtact ewithhfinntherwhyfirocarbon"vapors to b egonverted:

Operationsnfi the. type: described are commonly designatedrsflnirktatelystapnoeessesr In conventionatopera-tlonvspent' eat-allyst'tromth'e reaction zone is strippedlbyi -contactwilth:steamtnastripping zone; the; carbon -demsitea on-the catalyst particles is burned oil by contaot with aii "in-a regeneratingr'zone and the regenerated catalyst in=- fluid Emspension' is: returned to the "reaction zone 7 An importanttconsiderati'on in operatior'is,- et this "type; from a practice? aspect; is the effi'cient utilization'et the .atalyslz For 'maximum efileieney "it" is necessary-that all "ofthe eatalystbe 1 utilized to: 'equar exte'nh'im reaction zone andapaesecl to thetregenerator and that in the 40 I regenerator all thecatalystbemni'formly regeneratetl and returned to the reaction "zone. In operations ofthis type,-'-the"=.catalyst is usually maintainewthroug-hontthe system in afinidmalty not of" uniform "density throughout the "vailotls stages of *tl'l'eeoperatlon." m both'the reacti' n endregenerating zones, "and also in the a: zone i-f ieze 'ls'--norma;ll'y maintaineda seal sailed eigh density, or dense phese beey es; catalyst-oi: considerable: depth through which 'the-gaseeoi' -vapors passeml above" which the bodies at cejtalystlarein a continuously tur bulent state. Bcauseof condition; there irelied; technique-ihwatalgztioconversion, there is an "inherent disadvantage that the freshm- *cont ing cataly'st, partially"- spent catal yst and lst allee uselinlz l in? reflecting maximising-"and f'h'ae- 'spent catalystvin the"case'orthe reactor become intermixed in the catalyst "bed: when' eatalyst is withdrawri from thehetl for aegenerationyth is homogeneous mixtuneis-taken oflf= :amlmot atruly the fresh and spent catalyst, the effective activity "of'thecatalyst the bed isless:"than' if spent eatalyfl were'notalso present.

Similarly; the --strippei" and tnthe regeneraton'a more completestripping*arnd'lourifing strippedef-oil by oontact with-argaseous strinplhg 20" and" the regenerated and partiel'ly regenerated catalyst in"therespec-tive-zohes". V 5 1 Earthen-the eatalyst 'vapor contact inthere'aotor and in the'stl'ipper' 'andthe moh tactloetween the 'o atalyst and: r'genei'wtmg'galses' in the regenerat'or; are" not as dntimateand unif'orm as desirable: In the large turbulent"beds"'ofcatalyst there is a tendency" for "large-globules 1 of the va pers or gases to pass upwardly through the catalyst bed without "homing into mtimate contaet with the catalyst? Thepresent'inventtonprovides improved means of avoiding, to a major'erdtent at leastpolojectionable ihteimixing "of" the "catalyst in 'difiei'ent stagesof activity and for effectin g more uniform 7 contact between the catalyst and Vapors' or gases while maintainingthe fiuidizedmrinciple em eration.

In my eopencli'mg applicationgSerialNo. 757L643 filed 'eoncm'rentlyherewith; T have described and claimed improvednrethocl of operatiofiwherecy'I avoid the indiscfi'minate mixizig ofcatalyst ef different stages er ";ctiv'ation' in 'ther'eaotion zone, forinstanoei-by dividing the reactionchaminto a "plurality *of" 'vertioally' spa'ced' zones by a plurality of vertically spaced trays. A'bo'dy of dense phase fluidized catalyst is maintained on each of the trays. Regeneratedoatalyst is introduced into an 'end zone of the =chamber "and is passed throngh=the'oharfiber'trom tray to tray,

advantageously moving across each tray,-until it reaohesthe other-end zone of tliechamber; from warhioh "it' is "withdrawn 'and passed tothestribping zone. The hydrocarbon vapors to be converted are introduced into the lower zone of the chamber and pass upwardly therethrough in contact with the catalyst on the successively higher trays. In this way, top-to-bottom mixing of the catalyst is prevented and the hydrocarbon vapors are passed in contact with catalyst of progressively greater or lower catalytic activity, as they pass through the reaction chamber.

Further, the process provides a novel method of increasing the extent and uniformity of contact between the vapors and the catalyst without objectionable mixing of catalyst of unlike activity. This is effected, in accordance with my present invention by passing the vapors through the respective bodies of catalyst as a plurality of restricted streams flowing at such velocity that a portion of the catalyst from the lower ends of the respective beds is entrained by the vapors and carried upwardly and thereafter I subject the resultant suspension to centrifugal forces whereby the catalyst is, to a large extent at least. separated from the vapors and returned directly to the bed from which it was carried by the vapor streams and is thereafter re-entrained by further vapors, as just described.

This method of effecting uniform and extended contact with the catalyst may, with advantage. be employed in the stripping of the catalyst and also in the regeneration of the catalyst, as well as in the reaction zone, and may be employed in any one, or more, of these zones. It may be used with particular advantage in the stripping of readily vaporizable hydrocarbons from the catalyst.

The apparatus of my present invention, in its broader aspect, comprises a vertically elongated chamber divided into a plurality of vertically pc sitioned zones by one or more trays extending generally horizontally across the chamber and having a plurality of downwardly projecting funnel-shaped members. Positioned coaxially with the respective funnels is an inverted 'J tube, the lower end of which is spaced vertically from the lower inner surface of the body of the funnel so" as to permit material in the funnel to flow into the lower end of the J tube. The upper end of the J tube is curved over at an angle of about 180" and has the cross-section of an open semicircle of approximately the diameter of the intermediate and lower sections of the tube. The tray may also be provided with a standpipe. advantageously valved, extending through the tray from a point somewhat above to a point just above the next lower tray.

My present apparatus may be used with particular advantage in the carrying out of the process just described and is applicable to the reactor, the stripper, and the regenerator, or any one or more of these chambers.

The apparatus of the invention is adapted to continuous operation. in carrying out the described process comprising a plurality of cooperating steps so coordinated as to constitute a unitary operation in which a charge of catalyst is repeatedly used, intermittently regenerated and returned to the reaction zone and in which increased catalytic efllciency and catalyst life is attained.

The invention in its broader aspect, is apher or may be fed to the lower end, in the sus-- pension in the vapors or gases for instance, and carried thereby from zone to zone upwardly through the chamber in suspension, with the described recirculation within the respective zones.

The invention will be more fully described and illustrated with reference to the accompanying drawings of which:

Figure 1 represents conventionally and somewhat diagrammatically a vertical section of a fluid catalyst cracking apparatus embodying my invention;

Figure 2 is an enlarged fragmentary view of the interior arrangement of the reactor, the stripper and the regenerator;

Figure 3 is a cross-sectional view of Figure 2 along the lines 3-3; and

Figure 4 is a somewhat enlarged cross-sectional view of the element 6 of Figure 2.

Referring more particularly to Figure 1 of the drawings, the apparatus indicated by the reference numeral l represents a generally cylindrical reactor provided internally with a plurality of trays 2 extending entirely across the reactor and dividing the reactor into a plurality of zones. As shown more clearly in Figures 2 and 3, the trays are made up largely of a plurality of uniformly spaced downwardly projecting funnelshaped members comprising cones 3 terminating at their lower end in a short vertically positioned tube or nipple 4. Coaxially positioned above each of the tubes 4 is a vertically positioned tube 5 of somewhat larger diameter, terminating at its lower end a substantial distance from the upper end of tube 4.

The upper end 6 of the tube 5 has the crosssection of an open semicircle of approximately the diameter of the intermediate and lower sections of tube 5, as more clearly shown in Figure 4, and is curved over at an angle of approximately so as to form an inverted J tube. For counter flow of catalyst and gases alternate sides of opposite trays may be provided with standpipes I, in which there is interposed a valve arrangement 8, for instance, a conventional butterfly valve controlled by shaft 9, the standpipe projecting from a substantial distance above one tray to just above the next lower tray and there terminating in a trap or seal I 0. Line H leads into the lower end of the trap terminating beneath standpipe I.

In operation, the catalyst suspended in charge oil vapors is passed to the lower zone of reactor I through elevator conduit [2 upwardly through tubes 4 and is separated from the conve ing medium forming a dense phase body of fluidized catalyst on the lower tray 2. A portion of the catalyst is carried by the vapors upwardly into the next higher zone forming a dense phase bed of catalyst on the next higher tray and so on until each of the trays is filled. The bed of catalyst will build up on the respective trays to a depth such that the rate of carry-over of the catalyst to the next hi her tray equals the rate at which the catalyst is introduced to the lower zone of the reactor. By properly proportioning the areas and lengths of the risers, the dense phase catalyst bed may be caused to occupy a major portion of the volume of the reactor.

Vaporized feed oil, charged to the lower zone of the reactor through line l2, passes upwardly therethrough at a relatively low velocity until it reaches the lowermost tray 2 and passes upwardly through tubes 4 into the lower end of the respective co desired number n 5 By reason of the restricted area,theihyd rocarbonwaporsirpassnipwerdly through tubes 4 at Ya relatively high:meloelty:and iromsthence; supwardiylthroughztlfrespectivetuhes i, carrying in the: respective: conical -members; 1 Upon entering change-insnirection: of new; a large-portion ofthe catalyst is thrown outnf suspension centrifuforceunn'rh returned (directly;- to'the bed of catalyst omtheztrays:

Ont-passing?iromttuhes 5, "the "velocity: ofethe hydroearbmivaporsiis mgeinrreduced; and a further portion ofath'e': cetaiyst'eairriedin suspension -thlereiniisiprecipitateds' Imizveontinuingethein Zmplwerd 'ap assage: through .suspension'ifirielyl divided? natalyst picked .npin "theiupper portion 1:6 bfctubeseS, :hy'r reason-of the the:reaietor the:lizsniroacathom vapors; encounter the? nextr. higher stray :2 v 'ands the procedure" just describedais itheremepeateclvr r Ini thezdreiwing -nnl'y: threeesueh treys have been SHOWHYIhOWBVBtfiitA'Willib understood thatany strays may be employed The hydrocarbonjwaporsxinlithe uppenzone of theareactorihave been =uniformlya-contaotetl with this catalysts/and thereonversionnthereoi';eiiected.

These vanms pessrdiromrthe upper portion of the "reactor tlnroughtocynione type separator. l3, for

:th'e tseparatiomrorsuspendectcataiystpend pass therefrom through conduit 44 to iractiona-ting "apparatus, notlshown in theidrawingz Separated .ste am efor instence: :is introduced into: the lower emtof't'hestripper threughilineiflf and nistrihuter plate" l 9 and upasses zaipwandiy :"therethrou ghin eontaictwith the dawnwardlt 'grevitetin'g' catalyst:

in --the".resneetivelizonesv'F I have deseribed mncurrent flow-in the -reactor.

:Cduntercurrentfi'fiow will be: illustrated in? the "stripper-aim regeneratoi'rr The systemrshovm is spar-titular!!!radi'entageonsi as; it: necessitates the use'etonly one elevation of-i the catalyst'endsimplifies conveyance of themataiystsimmfrzoneto zoi'ie -v r The lnternal errengementmt the: stripper-and the iregeneratorfare: substantially as :rlescribed 1.

with tefefencerto: the reactbmexcept that in em eurrent flow the'rstamipipeszfl "are mot required, r the desmhjtlcnr queens mot- *b e atedzlike DhttS- bflillEilldlCflitBdlb? like retereneer numerals.

from-the cetzrlysttpesssirom the unmet:qaortion of thezstripner' through iinefi 8' the: upper nor tionwfthe'reectnm V 'Catelystrwhi-ch hast-been: "stripped: 'bymontaet withrthe strippingaanediuin :flowsvfromr the lower enriwofi the strippenthromzhtconduit 2i; into'the limestoneaofthezregeneretorz 2+; which is iprovided with trays such ns describdwith' reference; w the reeetor'and'the stripper; likeiparts'being indicated bydike' refereneernumeralsxthe detailed" descriptic m'of which needmot herehe' repented;

The ecaztalysti' igl'avitartes;downwardly "through the regenerates, essprevionsiy:described; countercurrent-tom -streameot air? introduced into the lower-emit oitheiregenerator'through "line 2 3 and r.

distributor*plnteekendw the :carhonaceous'deposit is *hurned'niifi ithe'nefrom'rhy content-With -the vair.

The productslnt eombustion pass from" (the "upper end of the regenerator through cyclone type sep- Steamy togethers 'witit hydrocarhnns' stripped 6 tom precipitetori-z orsstacku notashown "ins-the -drawiingz The regeneratorzmambezprovidedzwith convert.- tiona'lnmee'ns: fonzaextractingzrfromzthe vecattalyst nmd'e'rgoingiregeneretion, am amount'rof heatsufficienteto prevent;:excessivevtemperature rises,

Regeneratedetetalyst:zflowsa'fromr-thezbottomrof th'B-l regenerator: I through; conduit; 21; :at a a rate controlled: by waive- 28; into the zlower rendzof --e1ewater: :Conduilt n! 2-, cwhererrit :is .:picked uprbysthe stneamnf mpor-izmschargemihand; carriediupiinto and:through:thewreaetoriaszpreviouslydescribed. In countereurrent flow as in 'theistripperand thezreg enemtcr two eltemateomethodsof weretion.imayibeiemployecl. One istozso proportion the areas'zendilengths OfdlheTiSGrs thatzsome cat .al-rstswill: )fidiXCidOWIlWE rdwfrom: plate to, plate: in snitei oft-the upwardr-mouement 'of :the wga-ses anrl the localized: recirculation =01 catalyst our reach iplate. Downwerchflow of catalystcin the-risersrof such plates tBkESf D1M3T even when the normal vezoeities inwthezrisers careghigherthan these-requirecleior the"cateiystzcarryover; 1 The down fiow nfrctttaiiilsb results from: thiezsurging: that is tinherent in; a flniolizedzcetalyst ;bed;nwvhioh causes frequent iooeilehangesrimdensity; with the result th at torzeshort periorithezcaltalyst'm anyhow down some risers --while the vhulltlot: the 1 fluid stream gees up: others. A shift of bed wi-ll-rchangea this situation, causing" other: risers; to firop' catalyst dnwnwetrdmThistendenGy for ba'elefiow efrtatelyst diminishes eels ==the 'velocities end: pressure (ironinthe. risers increase. a

An nlternatexmethodanf' operation provides-for 'lpcsitivevdownflow :ofsthe eataiyst throughstencipipesfl, :moreccleeriyshewi'l in Figure, 2 of-athe dI'aWiTIQS'IF In i-thisismethod iof-woeeratienwthe staiidpipeswoperete: inset manner: similan tothe sta'ml pipesa cf: a conventini'ialrbubbleztower: The top of each stendpipe constitutesee, :weinwhich maintaine- 5 the level not:v the :dense rphase flu id catalyst: bed: air the desiieii- :de'pth on the plate. Theziower end at: this :standpipedipsinto a trap omsearonrthernext lowercplate; whiehsisrloelow the levele-bf-uthezdensez phaseifluida catalyst bed-V1011 this plate: This seal ereventstvgass from blowing up: the standpipees a resuitioflthe formation 'of a ilfilfitlilfilYLdEflSEl: best of icatariyst' in the stami pipes Insorcleritoainsure flow; of the catalyst in these standpipes smellvamountstof air'or steam arerdntroduoed' in: controlleflvquantities through lines/iii toxnaintain iluidization intheistantlpipes. Thisjharrangement: hassthe adv'antage of permitting: reletivelyihigh weloo'ities and: high recir cuiatiorrrrates onsthez pietes-w whilei at the same timednsuringvpositive zioW-nflow of the catalyst. Eithen'method 10f iopemtionis'alsoapplieableyto thereactor-as .well as; thewstripper and. regenerator: amt Eany mumheraofwtraysr may: he used in either.

By-zthezenrangement shown, objectionable mixme xif: cataiystvin'difierent stages of" activity is, tozza snatiori extent; avoided" and; theagese'ousme dim, that isghydroeerhdn sinners-,- strioning mediizmtorwregenerating' airfis brought into contact catalysthf unitorm:=eomncsiti.on and pmgressixzelyshigher-"m flower catalytic actz'u'ritt ini'theurespective' zones? The invention:istahnlicablei previously noted, toreithevtheireeetmiythestrin er a nd the regeneratesoreithertofithemz" The numberend tHEiItIfi-BSVBISBIflilhBIlSiGfiS of the risers t and '5 are; with iiadvantege; so coorclinatect with the V volnme'nofz gaseous medium; to' bee passed upwardarator 25 and:itrbmsthenoe through conduit 26 t ly therethrough that the suspensiommilimass riser tubes 5.

'standpipe, eifectively prevents the passage of upwardly through the risers at a velocity within the range of from 2 to 10 feet per second. At such velocities, maximum entrainment of the catalyst in the conical members 3 is attained.

In addition to use in the effecting of uniform contact between a gaseous medium and a finely -divided catalyst, the apparatus of my invention, 'as previously noted, is also applicable to the frac- The depth of the dense phase body of catalyst on the respective trays may be controlled by adjustment of the valve 8 in the standpipe I so as to maintain a substantial depth of catalyst above the upper end of standpipe 8 which, to-

gether with the body of catalyst within the vapors upwardly therethrough.

The catalyst is thus caused to flow generally horizontally across the respective plates while being repeatedly suspended in and separated from the rising vapors. On reaching the standpipe 1, the catalyst passes to the next lower tray and flows thereon substantially horizontally in the opposite direction across that tray while again being repeatedly suspended in and separated from the gaseous medium.

The diameter of the lower opening in the funnel-shaped member may be varied somewhat depending upon the number of funnel-shaped members in the respective trays and the relative velocities desired. Generally, these openings should be relatively small so as to afford 'large entrainment areas relative to the volume of gases passed therethrough. Such openings of about 1 to 3 inches in diameter will give highly effective results.

It is usually advantageous that the inner diameter of the bodyportion of the J tube be somewhat larger than the lower opening of the funnel so that the major portion, at least, of the gas stream passing through the funnel, is jetted directly into the body portion of the J tube. For

"instance, with a lower funnel opening of two inches in diameter, the opening through the body portion of the J tube may, with advantage, be about 2 /2 inches in diameter.

The catalyst may be of the type conventionally used in fluid catalyst processes, for instance, a silica-alumina type catalyst in finely divided or powdered form. The reaction conditions may, likewise, be those conventionally used in operations of this type, and as understood by the art, the optimum temperatures and pressures will depend primarily upon the type of feed stock used, the particular catalyst employed and the reaction desired.

In cracking gas oil, for instance, the reaction temperature may, with advantage, be within the range of 800 to 1,000 F. and the pressure at the top of the reactor within the range of 5 to 25 pounds per square inch. The regeneration temperature may be within the range of 950 to 1,200 E, heat for the reaction being supplied largely by the hot catalyst passing from the regenerator to the reaction zone.

cesses, and to stripping and fractionating pro-- r cesses generally. 7

I claim: 1. Apparatus of the type described comprising a vertically elongated chamber, a plurality of vertically spaced trays extending generally horizontally across the chamber and comprising a plurality of downwardly projecting funnelshaped members open at their upper and lower "ends, an inverted J tube positioned above each funnel member so that its body portion extends substantially vertically and is coaxially positioned with respect to the respective funnels, having its lower end vertically spaced from the lower inner surface of the funnel and its upper end curved over at an angle of about 2. Apparatus of the type described comprising a vertically elongated chamber, a plurality of vertically spaced trays extending generally horizontally across the chamber and comprising a plurality of downwardly projecting funnelshaped members open at their upper and lower ends, an inverted J tube positioned above each funnel member so that its body portion extends substantially vertically and is coaxially positioned with respect to the respective funnels, having its lower end vertically spaced from the lower inner surface of the funnel and its upper end curved over at an angle of about 180 and of a transverse area smaller than that of the body portion of the J tube.

3. Apparatus of the type described comprising a vertically elongated chamber, a plurality of vertically spaced trays extending generally horizontally across the chamber and comprising a plurality of downwardly projecting funnelshaped members open at their upper and lower ends, an inverted J tube positioned above each funnel member so that its body portion extends substantially vertically and is coaxially positioned with respect to the respective funnels, having its lower end vertically spaced from the lower inner surface of the funnel and its upper end curved over at an angle of about 180 and of a transverse area smaller than that of the body portion of the J tube, the inner diameter of the body portion of the J tube being somewhat larger than the inner diameter of the smaller opening in the funnel.

4. Apparatus for effecting intimate and uniform contact between a finely divided fluidized solid and a gaseous medium comprising a vertically elongated chamber, a plurality of vertically spaced trays extending generally horizontally across the chamber and comprising a plurality of downwardly projecting funnel-shaped members open at their upper and lower ends, an inverted J tube positioned above each funnel member so that its body portion extends substantially vertically and is coaxially positioned with respect to the respective funnels, having its lower end vertically spaced from the lower inner surface of the funnel and its upper end curvedover at an angle of about 180, conduit means adapted to the introduction of the fluidized solid to an upper zone of the chamber, conduit means adapted to the withdrawal of fluidized solid from a lower zone of the chamber, conduit means adapted to the introduction of a gaseous medium to a lower zone of the chamber, conduit means adapted to the withdrawal of a gaseous medium from an upper zone of the chamber and a standpipe extending through each tray from a point substantially above the tray to a point just above the next lower tray- KENNETH MERLE WATSON.

No references cited. 

1. APPARATUS OF THE TYPE DESCRIBED COMPRISING A VERTICALLY ELONGATED CHAMBER, A PLURALITY OF VERTICALLY SPACED TRAYS EXTENDING GENERALLY HORIZONTALLY ACROSS THE CHAMBER AND COMPRISING A PLURALITY OF DOWNWARDLY PROJECTING FUNNELSHAPED MEMBERS OPEN AT THEIR UPPER AND LOWER ENDS, AN INVERTED J TUBE POSITIONED ABOVE EACH FUNNEL MEMBER SO THAT ITS BODY PORTION EXTENDS SUBSTANTIALLY VERTICALLY AND IS COAXIALLY POSITIONED WITH RESPECT TO THE RESPECTIVE FUNNELS, HAVING ITS LOWER END VERTICALLY SPACED FROM THE LOWER INNER SURFACE OF THE FUNNEL AND ITS UPPER END CURVED OVER AT AN ANGLE OF ABOUT 180*. 